Aerosol Package With Fermentation Propulsion

ABSTRACT

A method is provided for filling a container system for a cosmetic product that has a hollow pressure containment vessel defining a chamber that encloses a sealed, collapsible, air-less pouch container containing product to be dispensed. A fermentation propulsion system is provided between the inner wall of the chamber and the air-less pouch container. The fermentation propulsion system comprises a quantity of yeast able to generate fermentation gas within the chamber, a quantity of sugar for the yeast to consume to fuel the fermentation process, and a yeast extract to boost fermentation activity. The fermentation gas serves as propellant for dispensing the product by applying pressure to the pouch container. A valve is secured in the opening of the vessel such that the chamber is hermetically sealed, and so that product can be selectively dispensed from the vessel.

FIELD OF THE INVENTION

The present invention relates to an aerosol package with an environmentally friendly fermentation propulsion system. In particular, the present invention is directed to an aerosol package with a fermentation propulsion system wherein the product being dispensed is isolated from the fermentation propulsion system by being enclosed in an air-less pouch.

DESCRIPTION OF THE PRIOR ART

U.S. Pat. No. 4,017,602 to Cazorla et al. discloses a process for preparing products for use in aerosol form wherein the composition to be dispensed is inoculated with micro-organisms able to bring about fermentation with the giving off within the container of carbon dioxide gas which serves as propellant. Disadvantages of the system disclosed are that the microorganisms that inoculate the compound are dispensed along with the compound, and the system may also dispense any unpleasant odor that may be a by-product of the fermentation process.

U.S. Pat. No. 5,009,340 to Morane discloses a packing container containing product to be dispensed, and a fermentation propulsion system contained in a sealed flexible pocket 8 or sealed resilient envelope 212 that is placed in the product. The packet or envelope expands as fermentation gasses are produced and product is dispensed from the container. A disadvantage of the disclosed system is that during the process of filling product into the container and placing the pocket/envelope in the container, the product may be exposed to air. The exposure to air may result in degradation of the product prior to it being dispensed.

Accordingly, there is a need for a fermentation propulsion aerosol that better isolates the dispensed product from the propulsion system and air contamination during filling.

BRIEF SUMMARY OF THE INVENTION

An object of the present invention is to provide a package with a fermentation propulsion system wherein the product to be dispensed is isolated from the fermentation propulsion system by being enclosed in a sealed, collapsible, air-less pouch.

The present invention is a container system for a cosmetic product. A pressure containment vessel having a hollow body defines a chamber that encloses a sealed, collapsible, air-less pouch container containing product to be dispensed. Between the inner wall of the chamber and the air-less pouch container, a fermentation propulsion system is provided. The fermentation propulsion system comprises a quantity of microorganisms able to bring about fermentation to generate gas within the chamber, and a quantity of food for the microorganisms to generate the gas. The quantity of food is provided to generate gas in a volume sufficient to pressurize the chamber. The gas serves as propellant. A valve is secured in the opening of the vessel such that the chamber is hermetically sealed, and so that product can be selectively dispensed from the vessel.

In greater detail, the invention is a container including a pressure containment vessel having a hollow body defining a chamber. The hollow body has a first end with an opening into the chamber and a closed second end. Positioned in the hollow body is a container with a flexible wall defining a compressible reservoir for containing the product. The container has an outlet in fluid communication with the reservoir. The outlet is in or adjacent the opening of the hollow body. A valve is secured in the opening of the vessel such that the chamber is hermetically sealed. The valve housing is secured to the container such that the inlet port is in fluid communication with the outlet of the container. The valve selectively operable to dispense the product from the reservoir through the dispensing port. A fermentation-based propulsion system is positioned in the chamber between the container and the vessel. The propulsion system comprises a quantity of microorganisms and a quantity of food for the microorganisms. The consumption of the food by the microorganisms brings about fermentation to generate gas within the chamber which serves as propellant to pressurize the chamber. The quantity of microorganisms and quantity of food are selected to generate the gas in a volume sufficient to pressurize the chamber for dispensing the product. The volume of gas generated in the chamber exerts pressure on the flexible wall sufficient to dispense product when the valve is actuated.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of the container system of the present invention in a filled state with the valve depressed for dispensing product P;

FIG. 2 is a partial exploded view of the container system prior to assembly;

FIG. 3 is a sectional view of the container system prior to filling; and

FIG. 4 is a sectional view of the container system during filling.

FIG. 5 is a sectional view of an alternative embodiment of the container system.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIGS. 1-4, a container system for a cosmetic product is shown generally at reference number 2. The container system 2 includes a pressure containment vessel 4 having a hollow body defining a chamber 6. The vessel 4 has a first end 8 with an opening 10 into the chamber 6 and a closed second end 12. Provided inside the vessel 4 is a pouch-type container 14 having a flexible wall 15 defining a compressible reservoir 16 for containing a product P. The container 14 has an outlet 18 in fluid communication with the reservoir 16. The container 14 is positioned in the chamber 6 with the outlet 18 in or adjacent the opening 10.

A valve 20 comprising a valve actuator 21 and a housing 22 is secured in the outlet 18 of container 14 in fluid communication with the reservoir 16. Valve actuator 21 has a dispensing port 24 outside of the reservoir 16 and an inlet port 26 in fluid communication with reservoir 16. As illustrated, the inlet port 26 is inside reservoir 16, but alternative arrangements could be made. For example, the inlet port 26 of valve 20 could be connected to the reservoir 16 by way of a dip tube or other similar fluid passage (not shown). The chamber 6 is hermetically sealed by securing either a perimeter of the outlet 18 of the container 14 to the first end 8 of the vessel (illustrated in FIG. 5), or, as illustrated in FIGS. 1-4, by securing the container 14 to the inlet port 26 of the valve housing 22 and hermetically securing the valve housing 22 to the opening 10 of the first end 8 of the vessel. The container 14 is hermetically secured to the valve 20 or the vessel 4 by any well known means, such as, for example, gluing, welding, crimping, press fitting, over-molding, etc. In this way, the valve housing 22 and container 14 are hermetically secured to the vessel 4 such that the inlet port 26 is in fluid communication with the outlet 18 of the container 14. The valve actuator 21 is selectively operable to dispense product P from the reservoir 16 through the dispensing port 26.

As illustrated in FIG. 1, to dispense product P from a filled and pressurized container system 2, valve actuator 21 is depressed against resistance provided by, for example, a valve spring 23 positioned between opposing shoulders of valve actuator 21 and housing 22. Depressing the valve actuator opens valve inlet port 26, which is in fluid communication with valve dispensing port 24 by way of valve duct 25. Opening the valve inlet port 26 permits product P to flow in the direction of arrow 33 from the compressible reservoir 16 into inlet port 26, up through duct 25 and out through dispensing port 24. An actuator button 27 with a nozzle 29 may be provided to direct the product P laterally from the container system 2 where it is readily accessible to the consumer. The nozzle 29 may be provided with a venturi 31 or other structure to facilitate creation of a fine, mist-like spray pattern.

To pressurize the container system 2, a fermentation-based propulsion system 34 is provided in the chamber 6 between the pouch-type container 14 and the pressure containment vessel 4. The propulsion system 34 comprises a quantity of microorganisms 28 able to bring about fermentation to generate gas within the chamber and a quantity of food 30 for the microorganisms. The propulsion system 34 is inserted in the chamber 6 prior to insertion of the container 14 into the vessel 4 (i.e., into the chamber 6). After the container 14 is inserted in the vessel 4 and chamber 6 is hermetically sealed relative to the ambient atmosphere outside the vessel 4, the propulsion system 34 begins to generate gas via fermentation within the sealed chamber 6. The microorganisms (e.g., yeast) convert the food (e.g., sugar) into CO2 and alcohol. The gas generated via fermentation serves to pressurize the chamber 6 by building in quantity while the volume is constrained by the vessel 4 and the container 14 filled with product P. The quantity of microorganisms 28 and quantity of food 30 are each selected to generate via fermentation the gas in a volume sufficient to pressurize the chamber 6 to the degree desired without exceeding the pressure limit of the pressure containment vessel 4. The volume of gas generated in the chamber 6 exerts pressure on the flexible wall 15 of the pouch-type container 14 sufficient to dispense product P when the valve 20 is actuated (for example, by depressing valve actuator button 27 as indicated by downwardly directed arrows 32 in FIG. 1). Accordingly, the gas generated via fermentation serves as the propellant for product P.

The microorganisms 28 able to bring about fermentation are preferably yeast in a quantity of a few ml. The food 30 for the microorganisms 28 is preferably a sugar, also provided in a quantity of a few ml. The gas yielded by the fermentation is carbon dioxide (CO2) gas. The amount of CO2 gas generated by the yeast is determined by the amount of sugar added to the system. To yield higher gas production and correspondingly higher gas pressure within the chamber 6, proportionally more sugar is added to the system. The more sugar that is added, the more gas will be produced by the yeast to yield a higher pressure within chamber 6. The final pressure achieved is thus determined by the amount of food (sugar) provided to the microorganisms (yeast) in the system.

The propulsion system 34 may further include an activity booster in the form of a yeast extract added to the fermentation-based propulsion system. A suitable yeast extract is, for example, sold under the tradename Springer ® available from Bio-Springer, a subsidiary of the Lesaffre Group (Société Industrielle Lesaffre (S.I.L.)), Marcq-en-Baroeul, France. The yeast extract may include one or more of vitamins, amino acids, phosphates and ammonium sulfate. The yeast extract enhances the reproduction and growth of the yeast and accelerates the activity of the yeast in generating fermentation gasses. The yeast extract is added to the propulsion system at a rate of approximately 5 grams per liter of yeast and sugar.

For illustrative purposes, in FIG. 2 the quantity of microorganisms 28 and quantity of food 30 are shown being added to the chamber 6 from a microorganism supply tube 36 and a food supply tube 38, respectively. Each quantity is supplied into funnel 40, which directs the mixed microorganisms and food into chamber 6. However, the microorganisms 28 and food 30 may be provided to chamber 6 by other means, either separately or, for example, in a chilled pre-mixed state, as long as the fermentation process is not substantially underway prior to sealing of the chamber 6. Either or both the microorganisms 28 and food 30 may be provided in dry, powder form, or as a liquid or slurry. If the microorganisms and food are provided in dry or powder form, a quantity of liquid such as, for example, water, may be added to the propulsion system at any stage prior to the sealing of chamber 6.

The fermentation-based propulsion system 34 with yeast extract added begins to activate shortly after mixing in the chamber 6. Pressure begins to build inside the chamber 6 approximately 3-4 hours after the chamber 6 is sealed. Final pressure is reached approximately 36 to 48 hours after the chamber 6 is sealed. The fermentation process works best at a temperature of approximately 34 degrees C. The final pressure in chamber 6 is attained when the yeast has consumed all of the sugar supplied to the system. The yeast survives for approximately 6-7 months in the system. If additional sugar is added to the system while the yeast survives, additional gas and corresponding additional pressure can be generated.

Because the fermentation-based propulsion system is biologically safe and relatively slow to activate, the manufacturing, assembly and filling lines for the container system 2, including the filling of product P and the insertion of the fermentation-based propulsion components, do not require pressurized filling equipment (e.g., high pressure propellant supply tanks and lines), pressurized containment rooms, or the related safety equipment and structures (e.g., explosion proof walls and windows). The manufacturing assembly and filling lines for the container system 2 may be operated in ambient atmospheric conditions with minimal safety equipment and structures. The fermentation-based propulsion system is relatively slow to activate, so assembly and sealing of the chamber 6 need not be rushed. The relative speed of activation may be controlled to some degree by lowering or raising the temperature, or by managing the quantity of liquid. Unlike a typical aerosol, the product P is isolated from the propulsion system 34 and protected by being contained in the pouch-type container 14.

The product P can be filled into container 14 prior to, at, or subsequent to the assembly of container 14 into the chamber 6 to form the container system 2. For example, product P may be filled in container 14 prior to assembly of the container system 2, and therefore may be filled at a remote location from the assembly point of container system 2. This approach provides greater separation of product P from the propulsion system components, further assuring that no cross-contamination occurs.

Alternatively, in the case where the opening 10 in the pressure containment vessel 4 is too small to accommodate a pre-filled container 14, the pouch-type container 14 may have a first compressed configuration 42 during assembly of the system (illustrated in FIGS. 2 and 3) and a second expanded configuration 44 after filling of the product (illustrated in FIGS. 1 and 4). In the first compressed configuration 42, the pouch-type container 14 is, for example, flattened and curled slightly to facilitate insertion through opening 10 of vessel 4 during assembly of the system 2. As illustrated in FIGS. 2-4, the container 14 in the first compressed configuration 42 may be pre-assembled with valve 20, i.e., valve 20 may be hermetically secured in outlet 18 of container 14 prior to insertion of the container 14 into the chamber 6 of vessel 4. The container 14 in the first compressed configuration 42 pre-assembled with valve 20 may then be inserted into the chamber 6 of vessel 4. After the container 14 is inserted in vessel 4, valve actuator 21 is depressed in the direction of arrows 46, and product P may be injected into container 14 through dispensing port 24 and inlet port 26 as illustrated by arrows 48 and 50, respectively. Injection of the product P into container 14 causes container 14 to expand to the second expanded configuration 44. Product P is preferably injected into container 14 after container 14 has been positioned in the chamber 6 but prior to hermetic sealing of chamber 6. By injecting product P prior to sealing chamber 6, excess air in chamber 6 is expelled prior to sealing. Alternatively, product P may be injected under pressure into container 14 after chamber 6 is hermetically sealed, thus building pressure in chamber 6 of the vessel 4 that can later be used to expel product from container 14 when the valve actuator 21 is depressed. In any case, the valve housing 22 of valve 20 may be hermetically secured in the opening 10 of the pressure containment vessel 4 to hermetically seal chamber 6 containing the pouch-type container 14 and the fermentation-based propulsion system 34.

The valve 20 of the container system 2 may include a neck fitment structure 52 for securing the valve housing 22 in the opening 10 of the vessel 4. As illustrated in FIGS. 1-4, the neck fitment structure 52 may be integrally formed with the valve housing 22. Alternatively, as illustrated in FIG. 5, the neck fitment structure 52 may comprise a separate part in the form of a collar or bushing structure 54 that connects the valve housing 22 to the opening 10 in the vessel 4. The collar or bushing 54 can be hermetically secured to the housing 22 by any well known means, such as, for example, gluing, welding, crimping, press fitting, threading, etc. Similarly, the fitment structure, whether integral with the housing 22 or a separate collar or bushing, may be hermetically sealed to the opening 10 of the vessel by any well known means, such as, for example, gluing, welding, crimping, press fitting, threading, etc.

The container system 2 may be refillable with product. For example, after all of product P has been dispensed from the pouch-type container 14, the valve 20 with a pouch-type container 14 attached may be selectively removable from the vessel 4. For example, the neck fitment structure 52 may be provided with threads or a bayonet structure that can be received in corresponding structure in the opening 10 in the vessel 4. A new valve 20 with a new pouch-type container 14 attached and filled with product P may be inserted and secured in the vessel 4. Alternatively, the original pouch-type container 14 can remain in the vessel 4 and be refilled with product P through the valve 20, i.e., by a process similar to that disclosed above for initially filling the container.

Similarly, the valve 20 may be selectively removable from the vessel 4 so that the propulsion system 34 can be recharged by providing a fresh supply of yeast and/or sugar.

As a working example, a container system 2 is provided with a pressure containment vessel 4 with a chamber 6 having a volume of 262 ml. A container 14 is provided in the chamber 6 of vessel 4. The container 14 has a reservoir 16 with a maximum volume of 150 ml when in the second expanded configuration 44. Product P is provided in the reservoir 16. The product P is provided in a quantity of 150 ml to completely fill the reservoir 16 in the expanded configuration 44. A fermentation-based propulsion system is also provided in chamber 6. The fermentation-based propulsion system comprises 1.25 grams of dry yeast, 11 grams of glucose water liquid mixture (prepared in a ratio of 250 gr of sugar per 1 liter of water) and 1.3 grams of yeast extract. If it is necessary to make the propulsion system more liquid, additional water may be added to the sugar and yeast. The foregoing quantities of yeast and sugar in the chamber volume stated above is expected to produce gas sufficient to pressurize the system to 6.5 bar at ambient external temperatures. The pressure achieved could obviously be effected by external ambient temperature extremes.

The advantages of the present invention include that a fermentation-based propulsion system is environmentally friendly. All of the propulsion system components are safe, biologically sourced, renewable and bio-friendly. Because the components of the propulsion system are plant based, and plants typically absorb CO2 to make sugar, there is no net increase of CO2 to the atmosphere. Also, the time to charge the system with pressure may be relatively slow. For example, the microorganisms (yeast) and food (sugar) in the absence of a booster will take approximately 5-6 hours to begin generating gas sufficient to charge the system. This slow charge rate allows for relaxed assembly of the components of the system at ambient pressure with no specialized pressure containment equipment or manufacturing spaces. This is in stark contrast to current propellants that may be flammable and/or used under high pressure, thus creating additional safety hazards and threat of injury to workers due to inadvertent burns, explosions or high pressure releases during manufacture. In addition, current propellants are known pollutants. The yeast and sugar of the present invention do not require any exceptional safety precautions or handling procedures, and are readily disposed of without difficult or expensive recycling processes. The propulsion system can be substituted for any current propulsion system (e.g., butane, di-methyl ether, CFC, etc.).

Because the system is a pouch system that isolates the product P from the propellant system 34 and does not rely on a dip tube, the consumer can dispense from the system with the system held at any angle, including upside down (in contrast to traditional systems that must be held upright to dispense product). An additional advantage of a sealed pouch-type system of the present invention is that if the reservoir 16 is sterilized prior to loading it with product P, it may be possible to reduce or eliminate preservatives in the product.

The products that can be dispensed from the system include sun spray, lotion, shaving gel or cream, liquid products or thick products. The system can be further used for toothpaste, food products (e.g., sauce, ketchup, mustard, mayonnaise, whip cream, cheese, etc.). The container system is airless, thus avoiding any potential contamination issues.

It is understood that various modifications and changes in the specific form and construction of the various parts can be made without departing from the scope of the following claims. 

What is claimed is:
 1. A method for preparing a pressurized product delivery package comprising the steps of: providing a pressure containment vessel having a hollow body defining a chamber, the hollow body having a first end with an opening into the chamber and a closed second end; providing a container and valve assembly, the container having a flexible wall defining a compressible reservoir for containing the product, the valve having a housing with a dispensing port and an inlet port, the valve housing adapted to be secured in the opening of the vessel, the valve housing secured to the container such that the inlet port is in fluid communication with an outlet of the container, the valve selectively operable to dispense the product from the reservoir through the dispensing port; inserting a fermentation-based propulsion system in the chamber to generate after a predetermined amount of time gas in a volume sufficient to pressurize the chamber, the propulsion system comprising a quantity of microorganisms able to bring about fermentation to generate gas within the chamber, and a quantity of food for the microorganisms; inserting the container portion of the container and valve assembly through the opening in the vessel such that the container is inside the chamber with the outlet in or adjacent the opening; securing the valve housing in the opening of the vessel such that the chamber is hermetically sealed; filling the reservoir with a quantity of product for dispensing; and storing the package for a period of time sufficient to allow the fermentation-based propulsion system to generate a desired volume of gas; wherein after storing, the volume of gas generated in the chamber exerts pressure on the flexible wall sufficient to dispense product when the valve is actuated.
 2. The method of claim 1 wherein the container is a flexible pouch.
 3. The method of claim 1 wherein the microorganisms comprise a yeast and the quantity of food comprises a sugar.
 4. The method of claim 3 further comprising an activity booster added to the fermentation-based propulsion system.
 5. The method of claim 4 wherein the booster comprises a yeast extract.
 6. The method of claim 5 wherein the yeast extract comprises at least one of vitamins, amino acids, phosphates and ammonium sulfate.
 7. The method of preparing a pressurized product delivery package of claim 1 wherein the container has a first compressed configuration and a second expanded configuration, the first compressed configuration adapted for the step of inserting the container portion of the container and valve assembly through the opening in the vessel, and the second expanded configuration adapted for receiving the quantity of product during the step of filling the reservoir.
 8. A method for preparing a pressurized product delivery package comprising the steps of: providing a pressure containment vessel having a hollow body defining a chamber, the hollow body having a first end with an opening into the chamber and a closed second end; providing a container and valve assembly, the container having a flexible wall defining a compressible reservoir for containing the product, the valve having a housing with a dispensing port and an inlet port, the valve housing adapted to be secured in the opening of the vessel, the valve housing secured to the container such that the inlet port is in fluid communication with the outlet of the container, the valve selectively operable to dispense the product from the reservoir through the dispensing port; filling the reservoir with a quantity of product for dispensing; inserting a fermentation-based propulsion system in the chamber to generate after a predetermined amount of time gas in a volume sufficient to pressurize the chamber, the propulsion system comprising a quantity of microorganisms able to bring about fermentation to generate the gas within the chamber, and a quantity of food for the microorganisms; inserting the container portion of the container and valve assembly through the opening in the vessel such that the container is inside the chamber with the outlet in or adjacent the opening; securing the valve housing in the opening of the vessel such that the chamber is hermetically sealed; and storing the package for a period of time sufficient to allow the fermentation-based propulsion system to generate a desired volume of gas; wherein after storing, the volume of gas generated in the chamber exerts pressure on the flexible wall sufficient to dispense product when the valve is actuated.
 9. The method of claim 8 wherein the container is a flexible pouch.
 10. The method of claim 8 wherein the microorganisms comprise a yeast and the quantity of food comprises a sugar.
 11. The method of claim 10 further comprising an activity booster added to the fermentation-based propulsion system.
 12. The method of claim 11 wherein the booster comprises a yeast extract.
 13. The method of claim 12 wherein the yeast extract comprises at least one of vitamins, amino acids, phosphates and ammonium sulfate.
 14. The method of preparing a pressurized product delivery package of claim 8 wherein the container has a first compressed configuration and a second expanded configuration, the first compressed configuration adapted for the step of inserting the container portion of the container and valve assembly through the opening in the vessel, and the second expanded configuration adapted for receiving the quantity of product during the step of filling the reservoir.
 15. A method for preparing a pressurized product delivery package comprising the steps of: providing a pressure containment vessel having a hollow body defining a chamber, the hollow body having a first end with an opening into the chamber and a closed second end; providing a container and valve assembly, the container having a flexible wall defining a compressible reservoir for containing the product, the valve having a housing with a dispensing port and an inlet port, the valve housing adapted to be secured in the opening of the vessel, the valve housing secured to the container such that the inlet port is in fluid communication with the outlet of the container, the valve selectively operable to dispense the product from the reservoir through the dispensing port; inserting a fermentation-based propulsion system in the chamber to generate after a predetermined amount of time gas in a volume sufficient to pressurize the chamber, the propulsion system comprising a quantity of microorganisms able to bring about fermentation to generate the gas within the chamber, and a quantity of food for the microorganisms; inserting the container portion of the container and valve assembly through the opening in the vessel such that the container is inside the chamber with the outlet in or adjacent the opening; securing the valve housing in the opening of the vessel such that the chamber is hermetically sealed; storing the package at ambient temperature for a period of time sufficient to allow the fermentation-based propulsion system to generate a desired volume of gas; and filling under pressure the reservoir with a quantity of product for dispensing; wherein after filling, the volume of gas generated in the chamber exerts pressure on the flexible wall sufficient to dispense product when the valve is actuated. 